BRH 501 Manual - Nordmac · iv hammer test 20 v safety precautions 21 grease schedule, torque and...

BRH 501 Manual Parts, Safety, Operation &Maintenance

Form No. M1075-POMS

Revision 0

March 2002

BRH 501 TABLE OF CONTENTS

INTRODUCTION 1TABLE OF CONTENTS 2

I MAIN DATA 3I-1 Overall dimensions 3I-2 Technical specifications 4

II MAINTENANCE INSTRUCTIONS 5II-1 Mounting tool and pin 5II-2 Lubrication 6II-3 Tool retainers 7II-4 Tool bushing and front guide wear parameters 8II-5 Side-rods 9II-6 Screws 10II-7 Accumulator 10II-8 Storage 11II-9 Underwater working 12

III OPERATING INSTRUCTIONS 14III-1 Cold weather starting 14III-2 How to obtain maximum productivity and long life 14III-3 How a demolition tool cracks rock and concrete 15III-4 Cause and effect of fatigue 15III-5 Demolition tool fatigue failure 17III-6 Typical failures 18III-7 TRAMAC demolition tool guide 18

IV HAMMER TEST 20

V SAFETY PRECAUTIONS 21

GREASE SCHEDULE, TORQUE AND OTHER SPECIFICATIONS 22

PARTS LIST P3CRADLE P4ACCUMULATOR P5

TROUBLE SHOOTING M1PART NAMES M4PARTS INSPECTION AND REASSEMBLING M5OVER SIZE BUSHING M13OPTION FOR UNDERWATER OPERATION M16

BRH 501 MAIN DATA

I MAIN DATA

I - 1 Overall dimensions

BRH 501 MAIN DATA

I - 2 Technical specifications

The oil supply ( respectively 30 gpm and 37 gpm for the BRH 501B(SB) andBRH 501C(SC) models) is the maximum oil flow setting allowed on thesehammers. The BRH 501B(SB) and BRH 501C(SC) hammers can be used withcarriers providing lower oil flows, but will produce lower blow rates. To main-tain an efficient hammer power, pressure adjustment shims have beendesigned [see paragraph II-2].

Oil temperature plays an important role as excessively hot oil increasesinternal leakage [which lowers efficiency] and deteriorates the piston sealsand the accumulator diaphragm.

501B 501SB 501C 501SC Impact class 1700 ft.lbs 2000 ft.lbs Oil supply 32 gpm 37 gpm Blows / minute 500 500 Operating pressure 1600 psi 1200 psi Max Back Pressure 45 psi 45 psi Height 84 in 84 in Working weight (lbs) 1500 2400 1500 2400 Shock absorber bracket No Yes No Yes Shock dampener in hydraulic circuit Yes Yes Tool diameter 4.5 in 4.5 in

Tool references Dimension P/N Standard moil point 39 in 26132 Long moil point 50 in 26133 Chisel 39 in 26136 Spade 8 in wide 26138 Blunt 39 in 26141

hammer excavator tank Maximum temperature 175 ºF 160 ºF

BRH 501 MAINTENANCE INSTR.

II MAINTENANCE INSTRUCTIONS

The life of a tool is determined by its operating time. The hour-meter of your excavator will not pro-duce an accurate measurement of the hammer operating time. Travelling and boom positioning areexcavator functions that consume a lot of time but do not involve actual hammer operating time.

II-1 Mounting tool and pin

When taking delivery of your new hammer, spend just a few minutes to familiarize yourself with thetool changing procedure.

II-1.1 To insert a tool

a> Insert the tool [rep. 350] into the front guide. Make sure that the two flat edges are well posi-tioned in order to insert the retaining pins. b> Using a screw driver, position lock [rep. 252] as to fully insert the retaining pin [rep. 251]. Thelock will release itself. Proceed the same way with the second pin.

Before inserting a new tool inside the hammer, make sure the shank of thetool, the bushing, and the two retaining pins are hand-greased [as a grease,we recommend the use of TRAMAC BRH7].

251252

251252


II-1.2 To remove a tool

a> Use a screw-driver to push in the lock [rep. 252] .b> Using another screw-driver, push retaining pin [rep. 251] out of hole B.c> Repeat on the other side for the second pin.d> remove the tool.

When removing the tool, take care not to drop the tool on sharp objects, or pol-ished surfaces may be damaged permanently.

II-2 Lubrication

The only routine maintenance for the TRAMAC models BRH 501B(SB) and BRH 501C(SC) is point lubrica-tion. It is essential and cannot be overlooked; it reduces considerably the frictions between the bushing andthe tool and lengthens the life of your hammer.

a> Before inserting the tool [rep. 350] inside the hammer, hand-greasethe shank of the tool, the bushing, and the two tool-retainers.

b> During normal daily operation, every two hours 20 shots with ahand operated grease pump in the grease fitting [rep. 258]. Use TRA-MAC BRH7 grease which may be obtained from your TRAMAC deal-er.

A properly lubricated hammer will show some grease running down the point :Keep the tool wet all the time.


II-3 Tool retainers

Examine the retaining pins [rep. 251] 2 or 3 times a week. Change themwhen they show signs of heavy wear (like becoming oval shaped orshowing big cracks).

When removing retaining pins, wear should be checked to decide if they should be turned over or not priorinserting in the front guide. In normal working conditions, the pins will show marks which correspond to theimpact of the upper round shoulder of the tool flat section. When controlling pins, two cases may arise :

a> Hollow shaped deformation without any bumparound the mark. Pin can be turned over by 180º tolengthen life time.

b> Hollow shaped deformation shows peripheric bumpmore particularly located on round part of pin.

Hollow shape

View F

F

View G

Bump

G


It is imperative to eliminate the bump by grinding prior turning the pin over 180 degrees.Deep and irreversible damages may result from ignoring the above mentioned recommen-dations and lead to forfeiture of warranty.

II-4 Tool bushing and front guide wear parameters

X

A

B


TRAMAC BRH 501B(SB) & BRH 501C(SC) fea-tures a replaceable chuck-bushing [rep. 255]. Thebushing and front guide must be regularly checkedfor wear. Excess wear will cause misalignmentbetween the tool and the striking piston. Thus, theimpact will generate stress contractions detrimentalto the striking faces.

Check wear regularly to be sure not to exceed 3/16 " between tool and bushing.When wear exceeds above indicated tolerances, consult your TRAMAC dealer forpart replacement.

II-5 Side-rods

Daily, inspect the side rods [rep. 300] for possible breakage or looseningby tapping on each rod with a metal object. You will notice if a rod is bro-ken by its particular sound.

Daily, check for loose tie rods. Consult your TRAMAC dealer for the tie rod tighten-ing procedure. It is a very sensitive undertaking and incorrect methods can resultin serious consequences. Your TRAMAC dealer knows the torque specificationsand will assist you in tightening the tie rods.

Rep. Designation Length (in) A Front guide diameter ? 4.605 B Chock bushing diameter ? 4.645 X Striking chamber length ? 4.290


II-6 Screws

II-6.1 BRH 501SB & BRH 501SC : Bracket cap bolts [rep. 310]

Check these 12 screws [rep. 310] and nuts [rep. 311] for tightness :o 30 minutes after having put the hammer into operation for the first time,o then weekly

The proper torque is 380 ft.lbs.

II-6.2 BRH 501SB & BRH 501SC : Wearing plates bolts [rep. 308]

Every 500 hours, check these 16 wearing plates bolts [rep. 308] for tightness. Theproper torque is 368 ft.lbs.

II-6.3 Accumulator fixing bolts [rep. 6]

Every 500 hours, check the 8 screws [rep. 6] for tightness. The proper torque is 470ft.lbs.

II-7 Accumulator

TRAMAC accumulators [rep. 2] should stay charged for at least one operating year. In normal operation, thetwo hammer hoses vibrate lightly; but when the accumulator is discharged, the hoses will jump violently. Youwill also note a power loss as the hammer will continue to fire, but will have no force.

Report this immediately to your TRAMAC dealer.


Check nitrogen pressure with test gauge P/N 21006 and, if necessary, recharge with charging fixtureP/N 51347.

TRAMAC accumulators do not loose their charge through leakage. A TRA-MAC accumulator consists of two flanges between which is held adiaphragm (reassembling a pie plate). The only time a TRAMAC accumulatorwill loose its charge will be when this diaphragm becomes perforated.

Never try to open the accumulator without discharging previously the pres-sure through the inflating screw.

II-8 Storage

Put the appropriate plugs on the hammer and excavator couplings, to avoid any oil leakage anddust penetration. Put the breaker away under cover in a clean place. Lubricate with grease the visi-ble part of the piston and the entire tool to avoid damage from rust.

Remember, a corroded piston destroys its seals in a few minutes.

This operation can't be overlooked in case of underwater work, and in partic-ular, in the case of sea water.

Accumulator pressure 530 psi Accumulator tightening screw [rep 4] torque 145 ft.lbs


II-9 Underwater working

The TRAMAC BRH 501B(SB) & BRH 501C(SC) modelsin the standard version must not be used for underwa-ter work, even for very short periods of time. If thechamber between the piston and the tool fills withwater when the piston strikes, the water will not beevacuated fast enough and a considerable pressurerise will then occur which will destroy the piston seal(with a risk of seizure).

II-9.1 Underwater kit

Position of the protecting plate


For underwater operation, two different procedures have to be following depending on the front guide yourhammer is equipped with :

case A : If equipped with new standard spacer (P/N 23830) and drilled front guide (P/N29209, installair-pressurization kit 79102

case B : If equipped with the old standard front guide (not drilled before 1978) and the old spacer(P/N21649 before summer 1989), install the new front guide (P/N 29209) and the new spacer (P/N23830)and air pressurization kit 79102.

Kit for air blowing

II-9.2 Compressor pressure

Pressure from the compressor must be at least 22 psi above the water pressure at the working depth.Consult the following chart to determine minimum pressure required at the corresponding depths.

Rep Qty Designation Part number 1 1 - Fitting 23832 2 1 - Knee piece 7295 3 2 - Lip seal 12817 4 1 - Screw 19716 5 1 Protecting plate (not provided w/kit

but to be welded on the cradle by the customer)

Water Depth Air pressure required (ft) (psi) 1 22

2.5 23 5 24

7.5 25 10 26

12.5 27 15 28

17.5 29 20 31

22.5 32 25 33

27.5 34 30 35

BRH 501 OPERATING INSTR.

III OPERATING INSTRUCTIONS

III-1 Cold weather starting

Start up the excavator and circulate the hydraulic oil to warm it upbefore starting the hammer. When oil is warm, raise the hammerfrom ground, idle the the engine and energize the hammer controlvalve. The oil will pass through the hammer but the hammer willnot fire. Run this way for 5 to 10 minutes; this will warm up thehammer parts. In below zero temperatures, we suggest the tool bestored in a warm shed at night. Extreme cold can crack the pointwhen you start the breaking operation.

III-2 How to obtain maximum productivity and long life

TRAMAC working tools are made from a special steel far superior to any tool steel commercially available.Unlike other tools on the market, our steel is hardened all the way through - no thin shell of hard steel whichwears quickly. When the tools lose their edge, either at the tip or on the sides, it is possible to sharpen themwithout repeating heat treatment, using one of the following methods :

A> With a milling or planning machine for chisels and cutters, or with a lathe for the moils and chisels.These operations must be completed using the adequate type of hard metal tool.

B> By sharpening : this operation must be performed using a coolant, in order not to overheat the toolto be maintained.

As a general rule, never let the tool cool quickly or suddenly, even when it is usedwith the breaker.

The fact of dipping a tool into water when it has been heated in the course of work, or leaving it in the snowin winter, results in a quenching effect on the tip or cutting bit, and this increases the risk of breakage.


Tools are covered by TRAMAC against metal defects (very uncommon). It is notunusual that some operations (working at angles, blank firing, ...) lead to toolbreakage, including inside the chuck housing.

The use of after market tools will void your warranty for any claim related to partsin contact with the tool (which includes the main piston).

Learning to run a hammer properly is not difficult. It takes a little time and just plain common sense. To pre-serve the life of the tool and obtain maximum hammer productivity, we urge you to read the following.

III-3 How a demolition tool cracks rock and concrete

When the hammer piston strikes the top of a demolition tool, it sends a compressive stress wave down to theworking end of the tool. Provided the demolition tool is in contact with the rock or concrete which requiresbreaking, it is this compressive stress wave which fractures the rock. Then, immediately following the com-pressive wave, a tensile stress wave is formed due to the hammer piston lifting from the top of the demolitiontool.

The cycle of compressive and tensile stresses flowing down the tool is repeated for each hammer blow.Obviously, anything that interferes with the strength of the compressive stress wave during service, for exam-ple "Blank Firing" or bending of the demolition tool due to leverage, will result in loss of breaker efficiency ofup to 80 % and possible failure of the tool itself.

III-4 Cause and effect of fatigue

III-4.1 Correct operating conditions

The continuous cycle of compressive and tensile stresses in the demolition tool, even under correct operat-ing conditions, creates fatigue stress in the tool which can lead to the fatigue failure of the tool before it isworn out. Anything which interferes with the cycle of compressive and tensile stresses will also increase thelevel of fatigue stress being applied to the demolition tool and, thus, increases the risk of early fatigue failureof the tool.


The main cause of increased fatigue stress in a demolition toolis any form of side pressure during service which creates bend-ing. Thus, utilizing the tool as a lever, using an incorrect drivingangle or attempting to break ground using the pull of the exca-vator are all detrimental to the life of a demolition tool andshould be avoided [see figure].

The hydraulic power available in the machine far exceeds the strength of ademolition tool if it is used incorrectly and can "snap the tool like a carrot".

III-4.2 Other causes of increased fatigue stress in a demolition tool include :

A> Free running ( or Blank firing)Free running occurs when the hammer piston strikes the top of the demolition tool when the workingend is not in proper contact with the rock or concrete to be broken. This includes jobs where the toolslides off the work and also when break-through of thin concrete slabs or boulders occurs.

B> Cold :Low temperatures cause a demolition tool to be more susceptible to fatigue failure. Tools should bewarmed before use.

C> Mechanical and thermal damage :Any form of damage to the surface of a demolition tool renders it more liable to suffer fatigue failure.Thus, all care must be exercised to prevent scratches, gouges or weld marks occurring due to acci-dental damage, galling caused by contact between the tool and chuck bushing trough the lack oflubrication or excessive bending.

D> Lubrication :Care must be taken to avoid metal to metal contact that, as a result of galling, could cause deepdamage marks which, in turn, may lead to the formation of fatigue cracks and eventually failure ofthe demolition tool. Make sure that the shank of the demolition tool is well lubricated before insertingit into the hammer.


E> Corrosion :A rusty demolition tool is more likely to suffer fatigue failure. Keep tools well greased and shelteredfrom the weather when not in use.

III-5 Demolition tool fatigue failure

Demolition tool fatigue failure will occur approximately 4 inches either side of the chuck front face[see figure] or through the retainer pin flat. Another slightly less common failure area can fallapproximately 8 inches from the working end, subject to the nature of use. The fracture face itselfwill normally exhibit semi-circular polished area with the remainder being of rougher appearance(see figure). The polished semi-circular area is the fatigue area and generally started from a dam-age mark or other stress initiated on the outside of the demolition tool and spread inwards.

The fatigue area slowly widens until the stresses being applied to the demolition tool cause suddenfailure of the remaining section. Generally, the size of the fatigue area indicates the level of stressapplied to the tool, i.e. the smaller the fatigue area, the higher the stress level, although it must beborne in mind that once initiation of a fatigue crack has taken place, it requires a lower stress levelto cause it to grow.


A B C D E F

Ref Tool type Application

A Moil point Low abrasive, homogenous materialB Chisel Plastic or heterogeneous materialC In-line chisel Plastic or heterogeneous materialD Blunt Crumbly rockE In-line asphalt cutter Asphalt cutter and trenchingF SpadeFrost Asphalt and trenching

III-6 Typical failures

TRAMAC demolition tools are manufactured from fist class materials and then heat treated to pro-duce a fatigue and wear resistant tool. Thus when a tool has apparently failed to give a satisfactoryservice life, a brief visual inspection can often give a quick indication about the cause.

Wear is dictated by the conditions of the material being broken, but, in general, the following guide-lines apply:

Blank tools worn more than 1/3 of their diameter, or moils and chisels worn back more than 2inches from the working end, are classed as reasonable life.

III-7 TRAMAC demolition tool guide


Fatigue breakage with typicalfatigue wrinkles due to steeldefect.100% WARRANTY

Failure due to blank firing orexcessive wear of bushingsand/or chuck housing.

NO WARRANTY

Failure due to- operation with worn out retaining pins,- blank firing,- twisting tool.

NO WARRANTY

Typical failure caused bymisalignment between downpressure, hammer and tool(prying, levering).

NO WARRANTY

Breakage due to impropercontact between the tool'stip and rock or concrete.

NO WARRANTY

Mushrooming or fast wearingcaused by operating too longon the same spot.

NO WARRANTY

BREAKAGE CHART

BRH 501 HAMMER TEST

IV HAMMER TEST

Measurement of the high pressure setting

For normal day to day work, TRAMAC's BRH 501 hammer has been pread-justed in manufacturing to obtain 1120 psi at 26 gpm for an oil temperatureof 110 ºF on a moderately hard ground.

Steel plate 1"min or hard rock

3/8" x 12' Hose

Gauge 0-3000 psi

MAX FLOW

RATE

MAX WORKING

PRESSURE

MAX BACK

PRESSURE

BRH 501B & 501SB 32 gpm 1600 psi 45 psi

BRH 501C & 501SC 37 gpm 1200 psi 45 psi

BRH 501 SAFETY PRECAUTIONS

V SAFETY PRECAUTIONS

1 Never use the hammer as a lifting device

2 Stay clear of hammer while in operation, flying objects can

cause severe injures, even death.

3 Be sure decals are clearly visible. Clean or replace as

necessary.

4 Activate the hammer only when the operator is seated in the

cabin with full-control of the machine.

5 Do not make any alterations to the hammer without

authorization from Tramac Product Support department.

6 Use only Tramac replacement parts.

7 The major hammer components are heavy. Take safety

precautions when handling.

8 When installing or removing hammer, keep hands and fingers

clear of mounting pin holes and linkage. Instruct operator to

touch controls only when signaled.

9 Be cautious of possible flying metal particles when striking

any hardened surfaces with a hand tool. Wear safety glasses

when performing such activities.

10 Wear ear protection if conditions warrant. Consult OSHA

regulations.

11 Use hammer for its intended purpose only.

BRH 501 GREASE SCHEDULE,TORQUE AND OTHER SPECS

ROUTINE MAINTENANCE AND LUBRICATION RECOMMENDATIONS:

The only routine maintenance for BRH is point lubrication. Incorrect lubrication can lead to scouring of pointand chuck housing as well as loss of production.

RECOMMENDED LUBRICANT - TRAMAC BRH-7 grease which may be obtained from your TRAMAC dealer.GREASING SCHEDULE - New points and tool retainers should be greased before inserting. Every 2 hours -20 shots with hand grease gun.

TOOL RETAINERS - Change when they show signs of heavy wear to avoid their breaking in chuck.

RECOMMENDED SPARE PARTS:

1) Seal seat2) Two tool retainers3) Grease fitting4) Spare tool

ACCUMULATOR NITROGEN CHARGES:

Check with test gauge 21006-LPressure = 530 psi

TORQUE SPECIFICATIONS:

Reference Number 6 = 500 ft-lbsReference Number 300 = 730 ft-lbsReference Number 308 = 365 ft-lbs1 x 13 1/2 Bolts = 150 ft-lbs - Notch on bolt head must line-up with mark in back head (Ref. 1). Remove tierod and nut in matched sets and replace in same location. Place arrow on nut so that it is not reversed.

SPECIAL TOOLS REQUIRED:

For Nitrogen charge:

- Pressure test gauge 21006-L- Charging fixture 30932-J

Page P1

BRH 501PARTS MANUAL

Form No. M1075-P

Revision 0

March 2002

BRH 501 PARTS LIST

Page P2

Page P3

BRH 501 PARTS LIST

Rep Qty Designation Part number Back Head ass'y, composed of :

1 1 - Back head 53221 3 1 - Nylon washer 18652 4 1 - O'ring 33616 2 1 - Accumulator 22848 5 2 - O'ring to s/n 20214 19856 5 2 - O'ring from s/n 20236 36579 6 8 - Screw 5 1/2" 24658 8 8 - Spring guide 22894 9 8 - Washer 22573 HP rotating connection ass'y, composed of :

10 1 - Knee part (1 "1/4 NPTF) 56047 11 1 - Threaded plug 21292 12 1 - O'ring 6711 13 2 - O'ring 5346

LP rotating connection ass'y, composed of :

10 1 - Knee piece (1"1/4 NPTF) 56047 11 1 - Threaded plug 21292 12 1 - O'ring 6711 13 2 - O'ring 5346 14 1 - Slide BRH 501B & 501SB 22974 or 1 - Slide BRH 501C & 501SC 22975 17 12 - 20 - Pressure adjustment shims 21291 15 1 - Spring slide 21289 16 1 - Barrel 21290 18 1 - Spring 18083

Distribution ass'y, composed of :

104 1 - Distribution box 19708 107 1 - Distributor 17678 106 3 - Piston 23062 105 1 - Distribution cover 23061 102 2 - Centering pin 19867

Cylinder ass'y, composed of :

100 1 - Cylinder 28362 108 2 - Lip seal 19698 103 1 - O'ring 19856

Striker ass'y, composed of :

150 1 - Piston BRH 501B & 501SB 19703 101 1 - Plunger 19171 150 1 - Piston BRH 501C & 501SC 19704 101 1 - Plunger 19170

Front guide ass'y, composed of :

250 250

1 1

Front-Guide (square retaining pins) Front Guide (round retaining pins)

29209 38939

259 1 O'ring 19856 255 1 Chuck bushing 20944 256 1 Pin 20948 257 2 Split pin 7046 254 4 Plug 7076 252 2 Bolt 22680 251 2 Retaining pin(square) 26130

BRH 501 PARTS LIST

Page P4

Page P5

BRH 501 PARTS LIST

Rep Qty Designation Part number 251 2 Retaining pin (round) 22679 253 2 Bolt spring 22681 262 1 Plug 38894 258 1 Oiler 6178 260 1 Spacer ass'y including : 23830 261 1 Wear bushing 2 3/8" 22448 261 1 Wear bushing 4" (ref. spacer 21649) 21768 300 4 - Side rods 57891 301 4 - Nuts 57369

BRH 501 CRADLE

Page P6

Rep Qty Designation Part number Heavy Duty Shock Absorbing Cradle :

304 1 - Cradle 26756 305 2 Stop 21032 306 8 Wearing plate 21028 307 8 Locking plate 21078 308 16 Screw 21159

7 8 Spring 21033 302 1 Top plate 21029 303 1 Shock absorber 21031 310 12 - Screw 31121 311 12 - Nut 5159

Page P7

BRH 501 ACCUMULATOR

BRH 501 Accumulator HP

Rep Qty Designation Part number 1 1 Lower flange 22847 2 1 Diaphragm 17639 3 1 Upper flange 26600 4 16 Screw 18645 5 1 Inflating screw 26248 6 1 Ring 14826 7 16 Plug 36306

Accumulator parts table

Maintenance accessories list

Recommended spare parts kit

Part name Qty P/N Seal kit 1 53247 Tools retainers 2 26130 Grease fitting 1 6178 Spare tool 1 26132

Tighten Bolts to 140 ft-lbs

Page P8

BRH 501 ACCUMULATOR

This Page Left Blank Intentionally

Cette Page est Laissée Blanche Intentionnellement

BRH 501 TROUBLE SHOOTING

Page M1

PANNES POSSIBLES … REMÉDESA - Fulte d'hulle au niveau du marteau.

Joints d'étanchéité endommagés ou usés.Consultez votre distributeur TRAMAC le plusproche.

B - Le marteau manque de puissance, les flexiblesde raccordement battent.

L'accumulateur est dégonflé, la membrane deI'accumulateur est percée. Vérifier la températurede I'huile. En cas d'échauffement important, fairevérifier par un technicien, le réglage des clapets dedécharge du circuit de pelle. Consultez votre distributeur TRAMAC le plus proche.

C - Le marteau fonctionne normalement puis lacadence ralentit et le marteau s'arrêite. Quelquetemps après le marteau redémarre puis s'arrête.

L'huile hydraulique est trop chaude.Le porteur doit être vérifié pour trouver l'origine del'échauffement. Si nécessaire réduire la pression defrappe du marteau.

D - Un tirant d'assemblage est cassé.

Arrdter le travail immédiatement.Consultez votre distributeur TRAMAC le plusproche.

E - Après adaptation au porteur, le marteau tapequelques coups puis s'arrête.

Le flexible retour est bouché, vérifier le coupleur (simontée).

Recommandation: Le brise roche ayant une puis-sance globale élevée, veiller au bon refroidissementde I'huile. Un mauvals réglage du clapet de sur-pression du porteur peut être la cause d'un échauf-fement important de I'huile entrainant un mauvaisfonctionnement du brise roche.

TROUBLES SHOOTING … REMEDIES A - Oil leakage on hammer.

Damaged or worn seals.Call your TRAMAC distributor.

B - The breaker loses power; high vibrations inbreaker hoses.

The accumulator is deflated or diaphragm punctured. Check the oil temperature.If oil is too hot, ask a technician to check the breaker circuit relief valve setting.Call your TRAMAC distributor.

C - The hammer operates normally, then slowsdown and stops. A few minutes later the hammerwill start again then stop again.

Hydraulic oil is too hot.Excavator circuit must be checked for heat source.If necessary reduce the breaker operating pressure.

D - One side rod bolt has broken.

Stop working immediately and call your TRAMACdistributor.

E - After connection to carrier, the breaker operatesfor few blows then stops.

The return hose is plugged, check the quick cou-pling seat (if installed).

Recommendation: Check oil temperature and settings of carrier relief valves. If relief valve is notadjusted properly, oil may heat up quicker due tothe high total power of rock breaker. This will causethe rock breaker to perform poorly.


TECHNICAL PROBLEMS

Before looking for a hammer problem, look for a problem in the installation, like bad quick couplers or aplugged filter [see page M3 for how to check the installation].

Make sure that the hammer has not been hooked up backwards.

Make sure that the hammer has the proper tool.

Make sure that the down pressure has been applied.

Make sure that no valve(s) are closed.

For any other problem, refer to the Trouble Shooting page M1. If you cannot identify the problem, BEFOREcalling your TRAMAC dealer, collect the following information. A complete diagnosis cannot be done withoutit.

Low Pressure Gauge 0-160 Psi

Return and Supply Lines (Same Size as Breaker)

Flow Meter

Flow Scale

Oil Temperature Gauge

Pressure Gauge

Needle ValvePage M2

A. Flow rate in high pressure line running to the hammer at operating temperature and operating pressure.B. Value of high pressure at hammer inlet when hammer is operating (use a 0-3000 psi gauge).C. Value of back pressure in return line (use a 0-160 psi gauge).D. Setting of relief valve in the system. For more details, please refer to page M3.


Page M3

How to check hydraulic circuit and installation

Mount a flow meter in place of the hammer. Also, mount a low pressure (0-160 psi) gauge on the outlet ofthe flow meter in order to test the back pressure in the return circuit

With the flow meter in place, activate the circuit and bring the machine up to operating temperature; do nottest the machine cold.

If the control valve is equipped with solenoid, switch on the solenoid before starting the engine to avoid damage to the flow meter. Do not switch on or off the solenoid when the engine is running. Adjust the flowoutput to match the requirements of the BRH 501B(SB) and BRH 501C(SC) - see table on page 20.

After the flow has been adjusted, load the flow meter to the hammer operating pressure value (see table onpage 20) plus 400 psi, and readjust the flow if necessary to keep the hammer flow value constant for pres-sure varying between 1000 psi and hammer operating pressure value (see table on page 20) plus 400 psi.

Relief valve problems

If you cannot reach the proper oil flow at the hammer operating pressure value plus 400 psi, you may have abad system relief setting or a bad hammer control valve.

To check system relief valve see excavator manual for proper relief setting. Build pressure with flow meter todetermine relief cracking pressure (usually 50 to 100 psi below relief setting). Reset relief if needed.

There should be 400 to 500 psi between hammer regulated pressure value and system cracking pressure orheat may develop.

Pump problems

If you cannot produce proper oil flow against pressure varying from 500 psi to hammer operating pressureplus 400 psi, the pump could be bad or there is excessive leakage in the circuit.

Hammer control valve problems

If relief valve and pump are good, open and close valve three or four times: The valve spool may be stickingor back pressure is developing on return line.

With the flow adjusted and the flow meter loaded to hammer operating pressure value plus 400 psi, takenote of the low pressure gauge reading.

The return pressure should be less than 45 psi. If the back pressure is more than 45 psi, the restriction caus-ing this higher pressure must be found and eliminated.

After the flow meter test is completed, disconnect the flow meter and connect the hoses to the hammer.Mount a high pressure gauge (0-3000 psi) on the hammer HP line and take the machine outside. Run thehammer on a heavy 3 inch by 40 inch by 40 inch steel plate on hard ground and take note of the pressurereading. Call your TRAMAC dealer if pressure adjustments are needed.

BRH 501 PART NAMES

Page M4

What to look for when assembling the BRH. NOTE: For general assembly procedure, refer to parts description.

BRH 501 PARTS INSPECTION ANDREASSEMBLING

Page M5

PARTS INSPECTION AND REASSEMBLING PROCESS:

Accumulator

1. Check o-ring seat “A” on lower flange. If damaged, polish with fine hand stone or remove 0.005” maximum.If the damage is too deep or more 0.005”, remove both sides according to “J” dimension.

2. Clean diaphragm groove “D.”

3. Check ring seat “E” on upper flange. Perfect seat only is acceptable.

4. Clean and check all bolts’ threads “K” in upper flange.

5. Clean and check all bolts “B.”

6. Mount new “BS” ring with hydraulic oil. IMPORTANT - DO NOT USE GREASE.

7. Make sure bores “L” are not plugged with rubber. Clean if necessary.

8. Reassembling, tightening and inflating, refer to specifications.

Page M6

Device for quick nitrogen pressure checking 21006:

- Made for service men or maintenance workshop.

- Direct reading of the existing pressure in accumulator on pressuregauge ref. 21013 fitted to the syringe.

- One only type of end part (ref. 21317) for breakers type BRH.

Instructions:- Clean out syringe.

- Suck up clean oil until syringe is full without air bubble.

- Put syringe end into accumulator grid hole and press withoutexcess (about 45 lbs.).When oil pressure into syringe equals nitrogen pressure,diaphragm is pushed down from grid, oil can flow out of syringeand appears on grid.Then nitrogen pressure in accumulator can be read on pressuregauge.

N.B. If control is affected on an accumulator taken from stock, oralready mounted on a BRH having not operated for quite sometime, the value read on pressure gauge may be higher then therecommended one. In this case diaphragm may be stuck on grid ormay have hardened, which causes further resistance. Accumulatormay however be used as such. If value is lower it is necessary tochange or repair the accumulator.

Inflating device for accumulator 41543:

- Make for service truck or maintenance workshop.

- Must be used together with a nitrogen tank.

Instructions:- Put accumulator inside fitting 41543, (1).

- Unscrew slightly five flat screws with spanner 21653, (2).

- Once connection to nitrogen taknk is made, open tank cock andadjust pressure to the required value by acting on expander .

- When pressure is reached, tighten five flat screw, close nitrogentank, open drain cock 11653, (3) and disconnect hose.

Nitrogen pressure in 400 and 450 accumulators is 525 to 555psi.


Page M7

Back head

PARTS INSPECTION:

9. Check all helicoils “B.”

10. Check o-ring seat “A.” Polish if necessary.

11. Check snap ring on slide sleeve inside tothe outlet port “E.”

12. Make sure that slide sleeve is tight in theback head and not damaged.

13. Make sure that side rod seat “D” is not damaged. If damaged, remove high spots onlywith hand fine stone or sand paper.

Side rod and nut

14. Make sure that the side rod seat “I” isnot damaged. Remove high spots only.

15. Check threads in side rod “H.”

16 Check thread in nuts.

17 Screw nut in side rod by hand. Make surethe nut screws in freely.

Note: When replacing broken side rod, it is recommended that all four (4) rodsare replaced.


Back head - distributor cover

18. Make sure that the seat “A” on the cover of the distributor is not damaged. Polish with hand finestone or surfacing plate, if necessary.Note: remove high sopt only, (maximum surfacing 0.003”).

19. Check seat “B” in the back head. Same procedure as no. 18.

Distributor cover - distributor box

20. Check seat “C.” If damaged, polish the highspot only with hand fine stone and repolish withfine compound, if necessary.

Distributor box - cylinder

21. Check seats “E” and “H.” If damaged, polishthe high spot only with hand fine stone and repolish with fine compound, if necessary.Note: Remove all compound before reassembling.

Page M8


22. Check plunger seat “A” on distributor cover.Polish if necessary.Note: Remove 0.004” max. only once. If you remove material, indicate how many times on the cover of the distributor.

23. Make sure that the piston “B” is not damaged.

Plunger

24. Make sure that area “C” on the plunger is notdamaged. If the damage is all around, mountnew plunger.

Distributor

25. Check the distributor seats, “B,” “H,” and “D.”Seat “B” - remove only once, a maximum of 0.004.”Seats “H” and “D” - just polish by hand. If the damage is severe or too deep, replace the distributor.

Distributor box

26. Check the internal distributor seat in the distributor box. Polish by hand. If the damage is severe or too deep, replace the distributor box.Note: If damaged by aeration or cavitation, check excavator hydraulic circuit or hydraulicfluid type.

Page M9


Page M10

27. Make sure that there is no obstruction betweenthe distributor and the distributor box. Insert the distributor into the distributor box and turn by hand. Make sure it turns freely. If not,use fine compound and polish.Note: Remove all compound before reassembling.

28. Do not remove the small orifice “A.”

29. Check seat “D” on distributor. If damaged,remove only once, a maximum of 0.004.”

Piston

30. Check seat “B,” perfect seat only is acceptable.

31. Check plunger seat “C.” Remove high spotsonly. If damage is too deep, replace piston.

32. Check area “E.” If damaged, remove high spotsonly. If too much damage, replace piston.

33. Check chrome area “H.” If damaged, useservice exchange if possible.

34. Check striking area “I.” If cracked or clenched,replace piston and check operating pressure, flowand tool alignment in chuck housing.


Page M11

Cylinder

35. Check internal surface in cylinder. If damaged, remove high spots only with hand fine stone. Polishthe surface.

IMPORTANT:Clean internal lube and alignment piston groove “A.”

36. Check seal groove edges “B.” If too sharp,smoothen by using a soft hand stone.

Note: Edge rodurs 0.008” +/- 0.004.” If the edgesare too sharp, peeling of chrome of the pistonwill occur.

37. Check o-ring seals “C” and “D.”

38. Wash and clean cylinder.


Page M12

Chuck housing

39. Make sure that the chuck housing is not crackedor damaged.

40. Check the wear on spacer bushing, on limit tool stroke area and inside the chuck housing.Note: Maximum wear depth is 0.125.” If more,install a new one. Refer to “48C.”

41. Make sure that the brass bushing in spacer bush-ing “B,” is not damaged. Important: If you install a new brass bushing,make sure that the piston strokes freely throughthat bushing. If not, polish with sand paper.

42. Clean the side rod boring “A” in chuck housingwith wire brush. Be sure that the side rod strokesfreely on nylon area.

43. Check lock plate retainer “C.” Refer to “55.”

44. Check the wear in bushing “D” (area “E”).Note: Maximum, allowed wear is 0.125.” If more,remove and mount a new bushing (refer to 45, 46,51, 52 and 53.

45. Make sure that the bushing “D” sits tightly in thechuck housing. If not, remve the existing bushing andmount a new one in place of the existing bushing. Note: Refer to over size bushing procedure draw-ing (page M13).

46. Check wear tolerance “H” between tool andbushign. Maximum allowed wear is 0.125.”


Over size bushing

Page M13

BRH 501 OVER SIZE BUSHING

47. Before you press the spacer bushing into the chuckhousing, freeze the spacer bushing in dry ice for onehour.

48. Maximum allowed wear of area “C” is 0.125.”

49. Clean the wall inside the chuck housing before youpress the spacer bushing. Note: Make sure that there is no obstructionbetween the spacer and the chuck housing wall.

50. If there is crack and shell on spacer area “C,” mounta new spacer and check the wear on bushing area.Refer to step “44,” area “E.”

51. Before you press the bushing “E” into the chuckhousing, freeze the bushing in dry ice for no less than 1hour.

52. The pin “H” locks the bushing in chuck housing.

53. The bushing press fit is 0.0023” +/- 0.0001 dia.Important: Check alignment of lock pin before youpress the bushing into the chuck housing.

54. Check the wear “K” on lock plate “N.” If too wornout, replace the lock plate with a new one.

55. Check lock pin assembly “P,” “O” and “T.”

Page M14


Page M15

Chuck housing

56. This model has no spacer bushing. The tolerance from tool stroke limit “A” is 0.190.”Note: Same check as “48.”

57. Clean the side rod boring “E” with a wire brush.Note: Be sure that the side rod strokesfreely on nylon area.

58. Make sure that the chuck housing “H”is not cracked or damaged.

59. Check “D” if the bushing is press fit intothe chuck housing “H.”

60. Over size bushing is available. Refer to over size bushing procedure drawing page M13.

61. Before you press the bushing “B” into the chuck housing, freeze the bushing in dry ice for minimum of one hour.

62. Before you press the bushing “B” make sure that the lock pin allignment is perfect.Refer to “53 - H.”

63. The tolerance between the chuck housingand wearing plate 306 is 0.060” (maximum). Add lock plate 307 in between cradle and wearing plate, if necessary.


BRH 501 OPTION FOR UNDERWA-TER OPERATION

64. Make sure that the nylon stopper 305 is notcracked or damaged.

65. Make sure that the nylon shock absorber 303 isnot cracked or damaged.

66. Make sure that the cradle is not cracked ordamaged. Reweld if necessary.

67. Check spring 7 for fatigue and cracks.

68. Make sure that the shock absorber retaining pin“A” is not cracked or damaged.

69. Chuck housing internal dimension area “A.”(97 +3 mm). Refer to page M13, area B.

Page M16

BRH 501 Manual - Nordmac · iv hammer test 20 v safety precautions 21 grease schedule, torque and...

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Transcript of BRH 501 Manual - Nordmac · iv hammer test 20 v safety precautions 21 grease schedule, torque and...